SPIRALLY WOUND CHANNEL CORE
A spool has a spirally-wound, elongated channel having a C-shaped cross-section with a pair of arms extending from a central web. The channel is oriented with the pair of arms parallel to the axis of the spool and with the central web extending radially, relative to the axis of the spool. The channel has a plurality of adjacent windings, a first and second of the arms of spirally-wound channel cumulatively forming the inner and outer surfaces of the spool. The arms are spaced apart a distance approximating the width of the central web, such that the central web of the windings of the channel is received between the arms of adjacent windings and is retained therein to establish an overlap of windings in the axial direction. Other embodiments feature S, B and E-shaped channels to form the spool, some embodiments having inner and outer layers of channel. The spool is suitable for holding wound, thin metal stock, such as aluminum for making beverage cans, having a smooth outer surface which preserves the smoothness of the wound stock.
The present invention relates to spools or “cores” around which thin stock materials, such as sheet metal, metal foil, wire, fabric or rope, may be wound to allow storage, transportation and/or handling of such stock materials, and more particularly, to such spools made from spirally wound material.
BACKGROUNDCoiled products, such as aluminum sheet and foil, must be stored on and transported to customers using a central spool or core about which the product is wrapped. The dimensions and characteristics of such cores are generally specified by the customers, and must be compatible with the customers' coil handling systems and minimize product damage during shipping and handling. For example, for high-volume, coiled aluminum sheet products, such as can stock, end stock and tab stock (all used in the manufacture of the aluminum beverage can), the cores used are typically thick walled tubes of laminated Kraft paper. Alternatives to paper cores, e.g., metal cores constructed by overlapping a corrugated strip into a spiral form around a mandrel are known.
SUMMARYThe disclosed subject matter overcomes the disadvantages and shortcomings of the prior art by providing a spool having an axis, an axial length, an inner surface and a curved outer surface about which material may be wound. The spool has a spirally wound, elongated channel having a C-shaped cross-section with a pair of arms extending from a central web, the channel being oriented with the pair of arms having a component of extension parallel to the axial length of the spool and with the central web extending radially relative to the axis of the spool. The channel has a plurality of adjacent windings, a first of the arms of spirally wound channel cumulatively forming the outer surface and a second of the arms of spirally wound channel cumulatively forming the inner surface, the first arm and the second arm spaced apart a distance approximating the width of the central web, such that the central web of the windings of the channel is receivable between the arms of adjacent windings and is retainable therein to establish an overlap of windings of the channel in the axial direction.
In accordance with an embodiment of the present disclosure, each of the first arm and the second arm has a first portion extending from the central web and a second portion extending from a free end of the arm to a transition portion extending between the first portion and the second portion, the second portion of the first arm and the second portion of the second arm having a first spacing there between approximating a second spacing between an exterior surface of the first portion of the first arm and an exterior surface of the first portion of the second arm.
In accordance with another embodiment of the present disclosure, the channel exhibits a third spacing between an exterior surface of the second portion of the first arm and an exterior surface of the second portion of the second arm and the difference between the second spacing and the third spacing approximates a radial thickness of the second portion.
In accordance with another embodiment of the present disclosure, the outer surface of the spool is cylindrical and smooth.
In accordance with another embodiment of the present disclosure, at least one of the first arm and the second arm has an undulating form in cross-section, an interior surface of the undulating form engaging and mating with an exterior surface of an undulating form of an adjacent winding of the channel of the spool.
In accordance with another embodiment of the present disclosure, both of the first arm and the second arm have an undulating form in cross-section.
In accordance with another embodiment of the present disclosure, the undulating form has first and second bulges separated by a valley, the first bulge extending from the central web.
In accordance with another embodiment of the present disclosure, the channel has at least one slot extending into the central web, the slot capable of receiving an end of at least one of the first arm and the second arm of an adjacent winding of the channel.
In accordance with another embodiment of the present disclosure, the slot is blind and is angled at an acute interior angle relative to the central web.
In accordance with another embodiment of the present disclosure, the channel has a pair of slots, a first slot disposed proximate a junction of the first arm with the central web and a second slot disposed proximate a junction of the second arm with the central web.
In accordance with another embodiment of the present disclosure, the first arm and the second arm each have an angled portion proximate a free end thereof which inserts into a corresponding one of the first slot and the second slot of an adjacent winding of the channel.
In accordance with another embodiment of the present disclosure, the channel has at least one groove in at least one of the first arm and the second arm disposed proximate the central web, and wherein at least one of the first arm and the second arm has an angled portion proximate a free end thereof which inserts into the groove of an adjacent winding of the channel.
In accordance with another embodiment of the present disclosure, the at least one groove is disposed between the central web and the first arm.
In accordance with another embodiment of the present disclosure, the at least one groove has a generally V-shaped cross-section.
In accordance with another embodiment of the present disclosure, at least one of the first arm and the second arm has a plurality of openings formed therein and from which a tab depends at an angle relative thereto proximate at least one of the openings, at least one of the plurality of openings aligning with the tab of an adjacent winding of the channel, the tab inserting into the aligned opening and aiding in securing adjacent windings of the channel in relative juxtaposition.
In accordance with another embodiment of the present disclosure, a spool has an axis, an axial length, an inner surface and a curved outer surface about which material may be wound and a spirally wound, elongated channel having an S-shaped cross-section with a pair of arms extending from a central web and having a component of extension in opposite directions. A first arm of the pair of arms has a first extension extending from an end of the first arm distal to the central web at an angle relative to the first arm and forming a top portion of the S-shape. A second arm of the pair of arms has a second extension extending from an end of the second arm distal to the central web at an angle relative to the second arm and forming a bottom portion of the S-shape, the second extension pointing towards a portion of the central web. A distal end of the second extension is distal to the second arm and is spaced from the central web by a first spacing, the channel being oriented with the pair of arms having a component of extension parallel to the axial length of the spool and with the central web extending radially relative to the axis of the spool. The channel has a plurality of adjacent windings, the first arm of adjacent windings of spirally wound channel cumulatively forming the outer surface and the second arm of adjacent windings of spirally wound channel cumulatively forming the inner surface, the first extension being receivable between the distal end of the second extension and the central web of an adjacent winding to interlock therewith and establish an overlap in the axial direction.
In accordance with another embodiment of the present disclosure, the distal end of the second extension pushes the first extension of an adjacent winding of the channel toward the central web.
In accordance with another embodiment of the present disclosure, a pushing arm extending from the distal end of the second extension, the pushing arm being captured in the interior angle formed between the first extension and the first arm.
In accordance with another embodiment of the present disclosure, a spool having an axis, an axial length, an inner surface and a curved outer surface about which material may be wound has a spirally wound, elongated inner channel with a first central web and a first pair of arms spaced a first distance from one another. The inner channel is oriented with the first central web having a component of extension parallel to the axial length of the spool and with the first pair of arms extending therefrom at least partially in a radial direction away from the axis of the spool. The inner channel has a plurality of adjacent windings, the first central web of adjacent windings of spirally wound inner channel cumulatively forming the inner surface. A spirally wound, elongated outer channel has a second central web and a second pair of arms spaced a second distance from one another. The outer channel is oriented with the second central web generally parallel to the axial length of the spool and with the second pair of arms extending therefrom at least partially in a radial direction towards the axis of the spool. The outer channel has a plurality of adjacent windings, the second central web of adjacent windings of spirally wound outer channel cumulatively forming the outer surface. The outer channel is wound over the inner channel with one of the first pair of arms positioned between the second pair of arms, such that adjacent windings of spirally wound outer channel bridge adjacent windings of spirally wound inner channel limiting axial motion of the outer channel relative to the inner channel and limiting spacing between adjacent windings of the inner channel and spacing between adjacent windings of the outer channel.
In accordance with another embodiment of the present disclosure, the first pair of arms converge towards one another at a distal end thereof and the second pair of arms converge towards one another at a distal end thereof, the first pair of arms with the first central web forming a triangular shape and the second pair of arms with the second central web forming a triangular shape.
In accordance with another embodiment of the present disclosure, a first arm of a first adjacent winding of the outer channel and a second arm of a second adjacent winding of the outer channel are disposed within a first triangular shape of a first adjacent winding of the inner channel.
In accordance with another embodiment of the present disclosure, a plurality of adjacent windings of the inner channel each capture the first arm and the second arm of adjacent windings of the outer channel within the triangular shape, thereby interlocking the inner channel and the outer channel.
In accordance with another embodiment of the present disclosure, a plurality of adjacent windings of the outer channel each capture the first arm and the second arm of adjacent windings of the inner channel within the triangular shape, thereby interlocking the inner channel and the outer channel.
In accordance with another embodiment of the present disclosure, the inner channel has a groove structure formed from a compound fold in the central web, the groove structure being disposed intermediate the first arm and the second arm, the groove structure of the inner channel defining an outwardly facing groove into which at least one of the first arm and the second arm of the outer channel is receivable.
In accordance with another embodiment of the present disclosure, the outer channel has a groove structure formed from a compound fold in the central web, the groove structure being disposed intermediate the first arm and the second arm, the groove structure of the outer channel defining an inwardly facing groove into which at least one of the first arm and the second arm of the inner channel is receivable.
In accordance with another embodiment of the present disclosure, the inner channel has a groove structure formed from a compound fold in the central web, the groove structure being disposed intermediate the first arm and the second arm. The groove structure of the inner channel defining an outwardly facing groove into which at least one of the first arm and the second arm of the outer channel is receivable. The outer channel having a groove structure formed from a compound fold in the central web, the groove structure being disposed intermediate the first arm and the second arm, the groove structure of the outer channel defining an inwardly facing groove into which at least one of the first arm and the second arm of the inner channel is receivable.
In accordance with another embodiment of the present disclosure, the outwardly facing groove is dimensioned to receive the first arm and the second arm of adjacent windings of the outer channel and the inwardly facing groove is dimensioned to receive the first arm and the second arm of adjacent windings of the inner channel.
In accordance with another embodiment of the present disclosure, at least one of the first arm and the second arm has a plurality of openings formed therein and from which a tab depends at an angle relative thereto proximate at least one of the openings, at least one of the plurality of openings aligning with the tab of an adjacent winding of the channel, the tab inserting into the aligned opening and aiding in securing adjacent windings of the channel in relative juxtaposition.
In accordance with another embodiment of the present disclosure, a spool has an axis, an axial length, an inner surface and a curved outer surface about which material may be wound.
A spirally wound, elongated inner channel has a first central web and a first pair of arms spaced a first distance from one another, the inner channel being oriented with the first central web parallel to the axial length of the spool and with the first pair of arms extending therefrom at least partially in a radial direction away from the axis of the spool. The inner channel has a plurality of adjacent windings, the first central web of adjacent windings of spirally wound inner channel cumulatively forming the inner surface. A spirally wound, elongated outer channel has a second central web and a second pair of arms spaced a second distance from one another, The outer channel is oriented with the second central web parallel to the axial length of the spool and with the second pair of arms extending therefrom at least partially in a radial direction towards the axis of the spool. The outer channel has a plurality of adjacent windings, the second central web of adjacent windings of spirally wound outer channel cumulatively forming the outer surface. At least one of the first arm and the second arm of at least one of the inner channel and the outer channel being scrolled inwardly toward the central web.
In accordance with another embodiment of the present disclosure, both the first arm and the second arm of at least one of the inner channel and the outer channel are scrolled inwardly toward the central web imparting a B-shaped cross-sectional shape.
In accordance with another embodiment of the present disclosure, both the first arm and the second arm of both the inner channel and the outer channel are scrolled inwardly toward the central web imparting a B-shaped cross-sectional shape, at least one of the inner channel and the outer channel having a spacing between the first arm and the second arm to accommodate at least one of the first arm and the second arm of the other of the inner channel and the outer channel therebetween.
In accordance with another embodiment of the present disclosure, both the inner channel and the outer channel have a spacing between the first arm and the second arm to accommodate at least one of the first arm and the second arm of the other of the inner channel and the outer channel therebetween. The outer channel is wound over the inner channel with one of the first pair of arms positioned between the second pair of arms, such that adjacent windings of spirally wound outer channel bridge adjacent windings of spirally wound inner channel limiting axial motion of the outer channel relative to the inner channel and limiting spacing between adjacent windings of the inner channel and spacing between adjacent windings of the outer channel.
For a more complete understanding of the present invention, reference is made to the following detailed description of exemplary embodiments considered in conjunction with the accompanying drawings.
The pre-form 12 is then bent (as shown by arrows A, B, C, D) into a modified C-shaped channel 20, which in cross-section, has two arms 22, 24 co-extensively extending away from the central web 14 in the same direction, approximately perpendicular thereto. Opposing end portions 22a, 24a of the web 14 of the pre-form 12, when bent, form portions of the arms proximate the central web 14, which have a spacing S1 between the outer surfaces of end portions 22a, 24a, approximating the interior spacing S2 between the arms 22, 24 proximate the opening of the C-shape. This bending to transition between the strip 10, to the pre-form 12, to the C-channel 20, can be accomplished by passing the strip 10 through roller dies (not shown) or a pulling it through a lubricated stationary die (not shown) or by or other conventional metal forming methods.
In the case of plastic, the C-channel 20 can be formed as a continuous extrusion from a melt or formed from a strip 10 that is deformable and settable, e.g., a thermoplastic via the application of bending and heating.
A guide roller 30 urged by force E, e.g., exerted via a resilient member or hydraulic actuation, may optionally assist in pressing the succeeding windings 20a, 20b . . . 20x of the C-channel 20 into an overlapping relationship to form the core 26. Alternatively, a guide surface tapering toward the core 26 and urging the C-channel 20 in the direction indicated by force E, may be used. A counteracting force F may be applied by a spring-loaded, rotatable, axially displaceable plate 311 (See
The C-channel 120 is oriented with the arms 122, 124 generally parallel to the outer cylindrical surface of a mandrel 128 and is wound about the mandrel 128 or otherwise urged (e.g., by a set of roller dies configuring a virtual mandrel) into a spiral shape. As shown in
As shown in
As shown in
Optionally, the slots 215, 217 may be crimped down onto the inwardly directed lips 223, 225 by a die acting internally to the C-channel 220b as it is coupled to the prior winding of C-channel 220a, i.e., by pressing against central web 214a. Crimping may also be accomplished by a crimping roller pressing the windings 220a . . . 220x against the mandrel 228 to diminish the distance between walls 222, 224, either independently, or in combination with crimping by an internal die.
The E-channel 550 is wound with the web portions 557, 559 thereof oriented generally parallel to the outer surface 5285 of the mandrel 528a and with the arms 553, 555 extending away from the mandrel 528. Successive windings 550a, 550b, 550x−1, etc. are wound in close proximity, one to another, such that the arms, e.g., 553b, 555a of adjacent E channel windings 550a and 550b touch, or are closely spaced. Since the core 526 shown in
As described above and shown in the Figures, the term “C-channel” has been used and is intended to describe a variety of channels having a C or modified C shape. The C-shape of the above-described C-channels has a pair of arms extending from a web, with each arm having a direction of extension with a component of direction parallel to the other arm of the pair. The arms are, in this sense, “parallel.” One or both of the arms may have one or more facets or curves, such that they are not completely straight, but nevertheless can be observed to have an average or general direction. Alternatively, the arms may be straight. An aspect of the cores described above which are formed from a spirally wound C-channel with the arms extending in a direction having a component of extension in parallel with the axis of the resultant core is that the webs thereof extend outwardly from the axis of the resultant spool/core with a component of extension perpendicular to the axis. The term “radial” is therefore intended to encompass extension perpendicular to the axis or extension which has at least a component of direction perpendicular to the axis of the spool/core. Cores made from the disclosed C-channel e.g., 20, 120, 220, 320, 420, 550, 671, 770, 827, 927 provide advantages in that the outer surface of the core (that which is in contact with the wound sheet or foil product) can be manufactured with a smooth face. This smoothness prevents the loss of inner windings of product that is wrapped on the core, e.g., 26, 827, 326. The webs, e.g., 14, 114, 214 provide an “I-beam” structure, a radially oriented spiral web, making the core stronger and more rigid for a given weight. The interlocking C-channels, e.g., 20, 120, 220, 320, 927 can be wound onto the mandrel 28 with a specified axial overlapping, such that the spacing of the radial webs 14, 114, 214 and the wall 36, 136, 236 bending stiffness are easily adjusted/set for a given application. Optionally, the axial overlap of C-channels, e.g., 20, 120 could vary across the axial length of the core. This provides the option of making a portion of the core, e.g., the ends, stronger relative to the remainder, attributable to greater overlap. The cores, e.g., 26, 326, 926 have a smooth inside diameter (ID), reducing the chance that the ID of the core will be damaged by handling equipment and facilitating interaction between the core 26, 326 and handling.
Cores 26, 326 made from the disclosed C-channel 20, 120 provide a double walled thickness to the desired degree via a selective degree of overlap. Double wrapped or composite cores 426, 526, 626 and 726 provide a double thickness wall 436, 536, 636, 736 with a variety of intermediate structural features to enhance strength and rigidity. The cores 626, 726 and 826 have resilient members that impart a degree of resilience to deformation forces. The core, e.g., 26, 326, 826 may be made from recyclable material and may be formed from the same composition as the sheet product being shipped. For example, an aluminum core 26, 326, 736 may be used to hold aluminum sheet. It is possible to construct cores 26, 326, 736 using sheet metal, which for various reasons, such as width, gauge, crystallographic texture, or staining, does not meet customer specifications and which would be scrapped. Use of scrap coils provides inexpensive and readily available feedstock material for the manufacture of the winding cores 26, 326. An all-metal core 26, 326, 626, 826 e.g., an all-aluminum core, can be conveniently recycled if it is constructed of the same or similar alloy from which the sheet product is produced, e.g., unused portions of the coils of sheet product on the core 26, 326 can be recycled together with the core 26, 326.
It is understood that the embodiments described herein are merely exemplary and that a person skilled in the art may make many variations and modifications without departing from the spirit and scope of the claimed subject matter. All such variations and modifications are intended to be included within the scope of the appended claims.
Claims
1. A spool having an axis, an axial length, an inner surface and a curved outer surface about which material may be wound, comprising:
- a spirally wound, elongated channel having a C-shaped cross-section with a pair of arms extending from a central web, the channel being oriented with the pair of arms having a component of extension parallel to the axial length of the spool and with the central web extending radially relative to the axis of the spool, the channel having a plurality of adjacent windings, a first of the arms of spirally wound channel cumulatively forming the outer surface and a second of the arms of spirally wound channel cumulatively forming the inner surface, the first arm and the second arm spaced apart a distance approximating the width of the central web, such that the central web of the windings of the channel is receivable between the arms of adjacent windings and is retainable therein to establish an overlap of windings of the channel in the axial direction.
2. The spool of claim 1, wherein each of the first arm and the second arm has a first portion extending from the central web and a second portion extending from a free end of the arm to a transition portion extending between the first portion and the second portion, the second portion of the first arm and the second portion of the second arm having a first spacing there between approximating a second spacing between an exterior surface of the first portion of the first arm and an exterior surface of the first portion of the second arm.
3. The spool of claim 2, wherein the channel exhibits a third spacing between an exterior surface of the second portion of the first arm and an exterior surface of the second portion of the second arm and the difference between the second spacing and the third spacing approximates a radial thickness of the second portion.
4. The spool of claim 3, wherein the outer surface is cylindrical and smooth.
5. The spool of claim 1, wherein at least one of the first arm and the second arm has an undulating form in cross-section, an interior surface of the undulating form engaging and mating with an exterior surface of an undulating form of an adjacent winding of the channel of the spool.
6. The spool of claim 5, wherein both of the first arm and the second arm have an undulating form in cross-section.
7. The spool of claim 6, wherein the undulating form has first and second bulges separated by a valley, the first bulge extending from the central web.
8. The spool of claim 1, wherein the channel has at least one slot extending into the central web, the slot capable of receiving an end of at least one of the first arm and the second arm of an adjacent winding of the channel.
9. The spool of claim 8, wherein the slot is blind and is angled at an acute interior angle relative to the central web.
10. The spool of claim 9, wherein the channel has a pair of slots, a first slot disposed proximate a junction of the first arm with the central web and a second slot disposed proximate a junction of the second arm with the central web.
11. The spool of claim 10, wherein the first arm and the second arm each have an angled portion proximate a free end thereof which inserts into a corresponding one of the first slot and the second slot of an adjacent winding of the channel.
12. The spool of claim 1, wherein the channel has at least one groove in at least one of the first arm and the second arm disposed proximate the central web, and wherein at least one of the first arm and the second arm has an angled portion proximate a free end thereof which inserts into the groove of an adjacent winding of the channel.
13. The spool of claim 12, wherein the at least one groove is disposed between the central web and the first arm.
14. The spool of claim 13, wherein the at least one groove has a generally V-shaped cross-section.
15. The spool of claim 1, wherein at least one of the first arm and the second arm has a plurality of openings formed therein and from which a tab depends at an angle relative thereto proximate at least one of the openings, at least one of the plurality of openings aligning with the tab of an adjacent winding of the channel, the tab inserting into the aligned opening and aiding in securing adjacent windings of the channel in relative juxtaposition.
16. A spool having an axis, an axial length, an inner surface and a curved outer surface about which material may be wound, comprising:
- a spirally wound, elongated channel having an S-shaped cross-section with a pair of arms extending from a central web and having a component of extension in opposite directions, a first arm of the pair of arms having a first extension extending from an end of the first arm distal to the central web at an angle relative to the first arm and forming a top portion of the S-shape, a second arm of the pair of arms having a second extension extending from an end of the second arm distal to the central web at an angle relative to the second arm and forming a bottom portion of the S-shape, the second extension pointing towards a portion of the central web, a distal end of the second extension being distal to the second arm and spaced from the central web by a first spacing, the channel being oriented with the pair of arms having a component of extension parallel to the axial length of the spool and with the central web extending radially relative to the axis of the spool, the channel having a plurality of adjacent windings, the first arm of adjacent windings of spirally wound channel cumulatively forming the outer surface and the second arm of adjacent windings of spirally wound channel cumulatively forming the inner surface, the first extension receivable between the distal end of the second extension and the central web of an adjacent winding to interlock therewith and establish an overlap in the axial direction.
17. The spool of claim 16, wherein the distal end of the second extension pushes the first extension of an adjacent winding of the channel toward the central web.
18. The spool of claim 17, further comprising a pushing arm extending from the distal end of the second extension, the pushing arm being captured in the interior angle formed between the first extension and the first arm.
19. A spool having an axis, an axial length, an inner surface and a curved outer surface about which material may be wound, comprising:
- a spirally wound, elongated inner channel having a first central web and a first pair of arms spaced a first distance from one another, the inner channel being oriented with the first central web having a component of extension parallel to the axial length of the spool and with the first pair of arms extending therefrom at least partially in a radial direction away from the axis of the spool, the inner channel having a plurality of adjacent windings, the first central web of adjacent windings of spirally wound inner channel cumulatively forming the inner surface;
- a spirally wound, elongated outer channel having a second central web and a second pair of arms spaced a second distance from one another, the outer channel being oriented with the second central web generally parallel to the axial length of the spool and with the second pair of arms extending therefrom at least partially in a radial direction towards the axis of the spool, the outer channel having a plurality of adjacent windings, the second central web of adjacent windings of spirally wound outer channel cumulatively forming the outer surface,
- the outer channel wound over the inner channel with one of the first pair of arms positioned between the second pair of arms, such that adjacent windings of spirally wound outer channel bridge adjacent windings of spirally wound inner channel limiting axial motion of the outer channel relative to the inner channel and limiting spacing between adjacent windings of the inner channel and spacing between adjacent windings of the outer channel.
20. The spool of claim 19, wherein the first pair of arms converge towards one another at a distal end thereof and the second pair of arms converge towards one another at a distal end thereof, the first pair of arms with the first central web forming a triangular shape and the second pair of arms with the second central web forming a triangular shape.
21. The spool of claim 20, wherein a first arm of a first adjacent winding of the outer channel and a second arm of a second adjacent winding of the outer channel are disposed within a first triangular shape of a first adjacent winding of the inner channel.
22. The spool of claim 20, wherein a plurality of adjacent windings of the inner channel each capture the first arm and the second arm of adjacent windings of the outer channel within the triangular shape, thereby interlocking the inner channel and the outer channel.
23. The spool of claim 22, wherein a plurality of adjacent windings of the outer channel each capture the first arm and the second arm of adjacent windings of the inner channel within the triangular shape, thereby interlocking the inner channel and the outer channel.
24. The spool of claim 19, wherein the inner channel has a groove structure formed from a compound fold in the central web, the groove structure being disposed intermediate the first arm and the second arm, the groove structure of the inner channel defining an outwardly facing groove into which at least one of the first arm and the second arm of the outer channel is receivable.
25. The spool of claim 19, wherein the outer channel has a groove structure formed from a compound fold in the central web, the groove structure being disposed intermediate the first arm and the second arm, the groove structure of the outer channel defining an inwardly facing groove into which at least one of the first arm and the second arm of the inner channel is receivable.
26. The spool of claim 19, wherein the inner channel has a groove structure formed from a compound fold in the central web, the groove structure being disposed intermediate the first arm and the second arm, the groove structure of the inner channel defining an outwardly facing groove into which at least one of the first arm and the second arm of the outer channel is receivable and wherein the outer channel has a groove structure formed from a compound fold in the central web, the groove structure being disposed intermediate the first arm and the second arm, the groove structure of the outer channel defining an inwardly facing groove into which at least one of the first arm and the second arm of the inner channel is receivable.
27. The spool of claim 26, wherein the outwardly facing groove is dimensioned to receive the first arm and the second arm of adjacent windings of the outer channel and the inwardly facing groove is dimensioned to receive the first arm and the second arm of adjacent windings of the inner channel.
28. The spool of claim 19, wherein at least one of the first arm and the second arm has a plurality of openings formed therein and from which a tab depends at an angle relative thereto proximate at least one of the openings, at least one of the plurality of openings aligning with the tab of an adjacent winding of the channel, the tab inserting into the aligned opening and aiding in securing adjacent windings of the channel in relative juxtaposition.
29. A spool having an axis, an axial length, an inner surface and a curved outer surface about which material may be wound, comprising: at least one of the first arm and the second arm of at least one of the inner channel and the outer channel being scrolled inwardly toward the central web.
- a spirally wound, elongated inner channel having a first central web and a first pair of arms spaced a first distance from one another, the inner channel being oriented with the first central web parallel to the axial length of the spool and with the first pair of arms extending therefrom at least partially in a radial direction away from the axis of the spool, the inner channel having a plurality of adjacent windings, the first central web of adjacent windings of spirally wound inner channel cumulatively forming the inner surface;
- a spirally wound, elongated outer channel having a second central web and a second pair of arms spaced a second distance from one another, the outer channel being oriented with the second central web parallel to the axial length of the spool and with the second pair of arms extending therefrom at least partially in a radial direction towards the axis of the spool, the outer channel having a plurality of adjacent windings, the second central web of adjacent windings of spirally wound outer channel cumulatively forming the outer surface,
30. The spool of claim 29, wherein both the first arm and the second arm of at least one of the inner channel and the outer channel are scrolled inwardly toward the central web imparting a B-shaped cross-sectional shape.
31. The spool of claim 30, wherein both the first arm and the second arm of both the inner channel and the outer channel are scrolled inwardly toward the central web imparting a B-shaped cross-sectional shape, at least one of the inner channel and the outer channel having a spacing between the first arm and the second arm to accommodate at least one of the first arm and the second arm of the other of the inner channel and the outer channel therebetween.
32. The spool of claim 31, wherein both the inner channel and the outer channel have a spacing between the first arm and the second arm to accommodate at least one of the first arm and the second arm of the other of the inner channel and the outer channel therebetween, and wherein the outer channel is wound over the inner channel with one of the first pair of arms positioned between the second pair of arms, such that adjacent windings of spirally wound outer channel bridge adjacent windings of spirally wound inner channel limiting axial motion of the outer channel relative to the inner channel and limiting spacing between adjacent windings of the inner channel and spacing between adjacent windings of the outer channel.
33. The spool of claim 1, wherein the overlapped windings of C-channel define an internal spiral hollow extending through the spool.
Type: Application
Filed: Jul 14, 2011
Publication Date: Jan 17, 2013
Inventors: J. Daniel Bryant (Murrysville, PA), Mark D. Crowley (Pittsburgh, PA), Daniel Bergstrom (Sarver, PA), Stephen J. Makosey (Export, PA), Glenn W. Jarvis (Allison Park, PA)
Application Number: 13/182,833
International Classification: B65H 75/10 (20060101); B65H 75/18 (20060101);